Owners Manual U4TVE4 1999

8/2/2019 Owners Manual U4TVE4 1999

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4TV-28199-E4

OWNERS MANUAL

YZF600R


2/109

EAU00001 INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of a YZF600R, you are benefiting from Yamahas vast experience in

and newest technology for the design and the manufacture of high-quality products,

which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your

YZF600Rs advantages. The owners manual does not only instruct you in how to

operate, inspect and maintain your motorcycle, but also in how to safeguard yourself

and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in

the best possible condition. If you have any further questions, do not hesitate to con-

tact your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to putsafety first!


3/109

EAU00005IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN-

VOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the

motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the

motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

NOTE:@

q This manual should be considered a permanent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.q Yamaha continually seeks advancements in product design and quality. Therefore, while

this manual contains the most current product information available at the time of printing,

there may be minor discrepancies between your motorcycle and this manual. If there is any

question concerning this manual, please consult your Yamaha dealer.@


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IMPORTANT MANUAL INFORMATION

EW000002

WARNING@

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING

THIS MOTORCYCLE.@


5/109

IMPORTANT MANUAL INFORMATION

EAU00008

YZF600R

OWNERS MANUAL

1999 by Yamaha Motor Co., Ltd.

1st Edition, August 1999

All rights reserved. Any reprinting or

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.Printed in Japan.


6/109

TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX

EAU00009


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1

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1


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1

1-1

1-GIVE SAFETY THE RIGHT OF WAY EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power andfreedom. However, they also impose certain limits, which you must accept; even the best motorcycle

does not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycles value and operatingcondition. Moreover, what is true for the motorcycle is also true for the rider: good performancedepends on being in good shape. Riding under the influence of medication, drugs and alcohol is, ofcourse, out of the question. Motorcycle riders - more than car drivers - must always be at their mental

and physical best. Under the influence of even small amounts of alcohol, there is a tendency to takedangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers andpassengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistantsynthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.

Optimum protective wear, however, should not encourage carelessness. Though full-coveragehelmets and suits, in particular, create an illusion of total safety and protection, motorcyclists willalways be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt totake chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,predictably and defensively - avoiding all dangers, including those caused by others.

Enjoy your ride!


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2

DESCRIPTION

Left view............................................................................................. 2-1

Right view........................................................................................... 2-2

Controls/Instruments.......................................................................... 2-3


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2-1

2

EAU00026

2-DESCRIPTION

Left view

1. Air intake duct (page 6-17)2. Fuel tank (page 3-11)3. Rear shock absorber spring preload

adjusting ring (page 3-18)4. Rear shock absorber rebound damping

force adjusting knob (page 3-18)

5. Rear shock absorber compressiondamping force adjusting screw (page 3-19)

6. Storage compartment (page 3-15)7. Helmet holder (page 3-15)8. Grab bar

9. Shift pedal (page 3-10)10. Radiator


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DESCRIPTION

2-2

2

Right view

11. Luggage strap holders (page 3-21)12. Rear brake fluid inspection window (page 6-25)13. Coolant reservoir tank (page 6-12)14. Front fork spring preload adjusting

bolt (page 3-16)

15. Front fork rebound damping forceadjusting screw (page 3-17)

16. Front fork compression dampingforce adjusting screw (page 3-17)

17. Rear brake pedal (page 3-10)


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DESCRIPTION

2-3

2

Controls/Instruments

18. Clutch lever (page 3-9)19. Left handlebar switches (page 3-8)20. Starter (choke) (page 3-13)21. Speedometer (page 3-6)22. Tachometer (page 3-6)

23. Coolant temperature gauge (page 3-8)24. Right handlebar switches (page 3-9)25. Front brake lever (page 3-10)26. Throttle grip (page 6-18)27. Main switch/steering lock (page 3-1)


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3

INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock......................................3-1

Indicator lights ......................................................3-2

Oil level indicator circuit check..............................3-4

Fuel indicator circuit check ...................................3-5

Speedometer ........................................................3-6

Tachometer ...........................................................3-6

Diagnosis device...................................................3-7

Antitheft alarm (optional) ......................................3-7

Coolant temperature gauge..................................3-8

Handlebar switches ..............................................3-8

Clutch lever...........................................................3-9

Shift pedal...........................................................3-10Front brake lever .................................................3-10

Rear brake pedal ................................................3-10

Fuel tank cap ..................................................... 3-11

Fuel .................................................................... 3-11

Fuel tank breather hose (for Germany only) ...... 3-13

Starter (choke) .......................................... 3-13

Seat.................................................................... 3-14

Helmet holder..................................................... 3-15

Storage compartment ........................................ 3-15

Front fork adjustment ......................................... 3-16

Rear shock absorber adjustment ....................... 3-18

Recommended combinations ofthe front fork and the rear shock absorber

settings............................................................. 3-20Luggage strap holders ....................................... 3-21

Sidestand ........................................................... 3-21

Sidestand/clutch switch operation check............ 3-22


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3-1

3

EAU00027

3-INSTRUMENT AND CONTROL FUNCTIONS

EAU00029*

Main switch/steering lockThe main switch controls the ignition

and lighting systems. Its operation is

described below.

EAU00036

ON

Electrical circuits are switched on. The

engine can be started. The key cannot

be removed in this position.

EAU00038

OFF

All electrical circuits are switched off.

The key can be removed in this posi-

tion.

EAU00040

LOCK

The steering is locked in this position

and all electrical circuits are switched

off. The key can be removed in this po-

sition.

To lock the steering, turn the handle-

bars all the way to the left. While push-

ing the key into the main switch, turn it

from OFF to LOCK and remove it.To release the lock, turn the key to

OFF while pushing.

EW000016

WARNING@

Never turn the key to OFF or

LOCK when the motorcycle is

moving. The electrical circuits will

be switched off which may result in

loss of control or an accident. Be

sure the motorcycle is stopped be-

fore turning the key to OFF orLOCK.@

1. Push

2. Turn


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3-2

3

EAU01590

(Parking)

The steering is locked in this position,and the taillight and auxiliary light come

on but all other circuits are off. The key

can be removed in this position.

To use the parking position, first lock

the steering, then turn the key to .

Do not use this position for an extend-ed length of time as the battery may

discharge.

EAU00056

Indicator lightsEAU00061

Neutral indicator light

This indicator comes on when the

transmission is in neutral.

EAU01313

Oil level indicator light

This indicator comes on when the oillevel is low. This light circuit can be

checked by the procedure on page 3-4.EC000000

CAUTION:@

Do not run the motorcycle until you

know it has sufficient engine oil.@

NOTE:@

Even if the oil is filled to the specified

level, the indicator light may flicker

when riding on a slope or during sud-

den acceleration or deceleration, but

this is normal.@

EAU01154

Fuel indicator light

When the fuel level drops below ap-

proximately 3.1 L, this light will come

on. When this light comes on, fill the

tank at the first opportunity. This light

circuit can be checked by the proce-

dure on page 3-5.

1. Neutral indicator light

2. Oil level indicator light

3. Fuel indicator light

4. Turn indicator light

5. High beam indicator light


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3-3

3

EAU00057

Turn indicator light

This indicator flashes when the turn

switch is moved to the left or right.

EAU00063

High beam indicator light

This indicator comes on when the

headlight high beam is used.

1. Neutral indicator light

2. Oil level indicator light

3. Fuel indicator light

4. Turn indicator light

5. High beam indicator light


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3-4

3

EAU00071

Oil level indicator circuit checkCB-48E

Turn the main switch to ON andthe engine stop switch to .


does not come on.


comes on.

Check engine oil level.

Oil level indicator lightcomes on.

Oil level indicator lightdoes not come on.

Engine oil level and

electrical circuit are OK.Go ahead with riding.

Put the transmission in neutral orapply the clutch lever, then pushthe start switch.

Oil levelis OK.

Supply

engine oil.

Oil levelis low.

Ask a Yamaha dealer to

inspect electrical circuit.


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3-5

3

EAU00085

Fuel indicator circuit check

CB-46E

Turn the main switch to ON and theengine stop switch to .

Fuel indicator light does

not come on.

Fuel indicator light

comes on.

Check the fuel level.

Fuel indicator lightcomes on.

Fuel indicator lightdoes not come on.

Fuel level and electrical

circuit are OK.Go ahead with riding.

Put the transmission in neutral orapply the clutch lever, then pushthe start switch.

Fuel levelis OK.

Supply fuel.

Fuel levelis low.

Ask a Yamaha dealer to

inspect electrical circuit.


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3-6

3

EAU00095

Speedometer

The speedometer shows riding speed.This speedometer is equipped with an

odometer and trip odometer. The trip

odometer can be reset to 0 with the

reset knob. Use the trip odometer to

estimate how far you can ride on a tank

of fuel. This information will enable you

to plan fuel stops in the future.

EAU00101

TachometerThis model is equipped with an electric

tachometer so the rider can monitor theengine speed and keep it within the

ideal power range.EC000003

CAUTION:@

Do not operate in the red zone.

Red zone: 13,200 r/min and above@

1. Odometer

2. Reset knob

3. Trip odometer

1. Tachometer

2. Red zone


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3-7

3

EAU00105

Diagnosis device

This model is equipped with a self diag-nosis for the following circuits:

q Throttle Position Sensor (T.P.S.)

circuit

q Fuel indicator light circuit

If some trouble should occur in any of

these circuits, the tachometer will re-

peatedly display as follows:CB-53E

Use this chart to identify what circuit is

faulty according to the specified r/min

displayed.CB-60E

If the tachometer displays as described

above, take note of the specified r/min

and then take your motorcycle to aYamaha dealer for repair.

EC000004

CAUTION:@

To prevent engine damage, be sure

to consult a Yamaha dealer as soon

as possible if the tachometer dis-

plays a repeated change in r/min.@

EAU00109

Antitheft alarm (optional)

An antitheft alarm can be equipped tothis motorcycle. Consult your Yamaha

dealer to obtain and install the alarm.

Specified r/min Faulty circuit

3,000 r/minThrottle Position Sensor

(T.P.S.)

8,000 r/min Fuel indicator light

0 r/min

for

3 seconds

Specified r/min for

the faulty circuit

for 2.5 seconds

(see chart below)

Current

engine

r/min for

3 seconds


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3-8

3

EAU01652

Coolant temperature gaugeThis gauge indicates the coolant tem-

perature when the main switch is on.The engine operating temperature will

vary with changes in weather and en-

gine load. If the needle points to the red

zone or higher, stop your motorcycle

and let the engine cool. (See page 6-41

for details.)EC000002

CAUTION:@

When the engine is overheated, do

not continue riding.@

EAU00118

Handlebar switches EAU00120Pass switch PASS

Press the switch to operate the passing

light.

EAU00121

Dimmer switchTurn the switch to for the high

beam and to for the low beam.

EAU00127

Turn signal switch

To signal a right-hand turn, push theswitch to . To signal a left-hand

turn, push the switch to . Once the

switch is released it will return to the

center position. To cancel the signal,

push the switch in after it has returned

to the center position.

EAU00129

Horn switch

Press the switch to sound the horn.

1. Coolant temperature gauge

2. Red zone

1. Pass switch PASS

2. Dimmer switch

3. Turn signal switch

4. Horn switch



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3-9

3

EAU00138

Engine stop switch

The engine stop switch is a safety de-vice for use in an emergency such as

when the motorcycle overturns or if

trouble occurs in the throttle system.

Turn the switch to to start the en-

gine. In case of emergency, turn the

switch to to stop the engine.

EAU00134

Lights switch

Turning the light switch to , turns

on the auxiliary light, meter lights and

taillight. Turning the light switch to turns the headlight on also.

EAU00143

Start switch

The starter motor cranks the enginewhen pushing the start switch.

EC000005

CAUTION:@

See starting instructions prior to

starting the engine.@

EAU00152

Clutch leverThe clutch lever is located on the left

handlebar, and the ignition circuit cut-

off system is incorporated in the clutch

lever holder. Pull the clutch lever to the

handlebar to disengage the clutch, and

release the lever to engage the clutch.

The lever should be pulled rapidly and

released slowly for smooth clutch oper-ation. (Refer to the engine starting pro-

cedures for a description of the ignition

circuit cut-off system.)

1. Engine stop switch

2. Lights switch

3. Start switch

1. Clutch lever



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3-10

3

EAU00157

Shift pedalThis motorcycle is equipped with a con-

stant-mesh 6-speed transmission.

The shift pedal is located on the left

side of the engine and is used in com-

bination with the clutch when shifting.

EAU00161

Front brake leverThe front brake lever is located on theright handlebar and is equipped with a

brake lever adjusting dial. To activate

the front brake, pull the lever toward

the handlebar.

To adjust the front brake lever position,turn the brake lever adjusting dial while

pulling the lever forward. Make sure the

setting on the brake lever adjusting dial

is aligned with the arrow mark.

EAU00162

Rear brake pedalThe rear brake pedal is on the right

side of the motorcycle. Press down on

the brake pedal to apply the rear brake.

1. Shift pedal 1. Arrow mark

2. Brake lever adjusting dial

3. Front brake lever

a. Lever distance

1. Rear brake pedal



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3-11

3

EAU02935

Fuel tank capTo open

Open the lock cover. Insert the key andturn it 1/4 turn clockwise. The lock will

be released and the cap can be

opened.

To close

Push the tank cap into position with the

key inserted. To remove the key, turn it

counterclockwise to the original posi-

tion. Then, close the lock cover.

NOTE:@

This tank cap cannot be closed unless

the key is in the lock. The key cannotbe removed if the cap is not locked

properly.@

EW000023

WARNING@

Be sure the cap is properly installedand locked in place before riding the

motorcycle.@

EAU01183

FuelMake sure there is sufficient fuel in the

tank. Fill the fuel tank to the bottom ofthe filler tube as shown in the illustra-

tion.EW000130

WARNING@

Do not overfill the fuel tank. Avoid

spilling fuel on the hot engine. Do

not fill the fuel tank above the bot-

tom of the filler tube or it may over-

flow when the fuel heats up later and

expands.@

1. Lock cover

2. Open

1. Filler tube

2. Fuel level



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3-12

3

EAU00186

CAUTION:@

q Always wipe off spilled fuel im-mediately with a dry and clean

soft cloth. Fuel may deteriorate

painted surfaces or plastic

parts.

q (For Germany only)

The fuel tank cap equipped on

German models is specially de-

signed. Always use the correct

cap whenever replacement is

necessary.@

EAU00191

NOTE:@

If knocking or pinging occurs, use a dif-

ferent brand of gasoline or higher oc-tane grade.@

Recommended fuel:Regular unleaded gasoline with a

research octane number of 91 or

higher.

Fuel tank capacity:

Total:

19 LReserve:

3.1 L



27/109


3-13

3

EAU00196

Fuel tank breather hose

(for Germany only)This model is equipped with a fuel tank

breather hose. Before using this motor-

cycle, be sure to:

q Check hose connection.

q Check hose for cracks or damage.

Replace if damaged.

q Make sure the end of the hose is

not blocked. Clean it if necessary. EAU02973Starter (choke) Starting a cold engine requires a richer

air-fuel mixture. A separate starter cir-

cuit supplies this mixture.

Move in direction a to turn on the

starter (choke).

Move in direction b to turn off the

starter (choke).

1. Fuel tank breather hose

1. Starter (choke)



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3-14

3

ECA00038

CAUTION:@

Do not use the starter (choke) formore than 3 minutes as the exhaust

pipe may discolor from excessive

heat. Also, longer use of the starter

(choke) will cause afterburning. If af-

terburning occurs, turn off the

starter (choke).@

EAU01591*

SeatTo remove the seat, insert the key into

the helmet holder lock and turn it as

shown. Then, lift the seat upward.

To install the seat, insert the projec-

tions on the front of the seat into the

seat holder, then push the seat down.

NOTE:@

Make sure that the seat is securely fit-

ted.@

1. Open 1. Seat holder

2. Projection ( 2)



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3-15

3

EAU00261

Helmet holderTo open the helmet holder, insert the

key in the lock and turn it as shown. Tolock the helmet holder, turn the key to

its original position.EW000030

WARNING@

Never ride with a helmet in the hel-

met holder. The helmet may hit ob-

jects, causing loss of control and

possibly an accident.@

EAU01688

Storage compartmentThis compartment is designed to store

a genuine Yamaha U-LOCK. (Otherlocks may not fit.) Be sure the lock is

fastened securely with the straps when

storing it in the compartment.

To prevent losing the straps, be sure to

secure them even when a U-LOCK is

not being stored in the compartment.

When storing this Owners manual or

other documents in the compartment,

be sure to put them in a vinyl bag sothey do not get wet. When washing the

motorcycle, be careful not to flood this

compartment with water.

1. Helmet holder

2. Open

1. U-LOCK

2. Strap ( 3)



30/109


3-16

3

EAU01862*

Front fork adjustment

This front fork is equipped with springpreload and damping force adjusters.

EW000037

WARNING@

Each fork leg must be set to the

same pressure. Uneven setting can

cause poor handling and loss of sta-bility.@

Adjusting spring preload

Turn the adjusting bolt in direction a

to increase spring preload and in di-

rectionb

to decrease spring preload.Align the preferred setting with the top

of the front fork cap bolt.EC000013

CAUTION:@

The grooves are provided to show

the adjustment level. Always keepthe adjustment level equal on both

fork legs.@

CI-18E

1. Spring preload adjusting bolt 1. Setting

2. Front fork cap bolt

HardStan-

dardSoft

Adjusting

position 1 2 3 4 5 6 7 8



31/109


3-17

3

Adjusting rebound damping force

Turn adjusting screw in direction a to

increase rebound damping force and in

directionb

to decrease rebounddamping force.CI-33E

Adjusting compression damping

force

Turn the adjusting screw in directiona

to increase compression dampingforce and in direction b to decrease

compression damping force.CI-33E

EC000015

CAUTION:@

Never attempt to turn an adjusterbeyond the maximum or minimum

setting.@

NOTE:@

Although the number of clicks between

the minimum and maximum settingsmay vary with each individual shock

absorber and may not exactly match

these specifications, it is always the full

damping force range that extends over

the actual number of clicks.@

1. Rebound damping force adjusting screw

Minimum (soft) 10 clicks out*

Standard 7 clicks out*

Maximum (hard) 1 click out*

* From the fully turned-in position

1. Compression damping force adjusting screw







32/109


3-18

3

EAU01592*

Rear shock absorber

adjustmentThis shock absorber is equipped with

spring preload and damping force ad-

justers.EC000015

CAUTION:@

Never attempt to turn an adjusterbeyond the maximum or minimum

setting.@ Adjusting spring preload

Turn the adjusting ring in directiona to in-

crease spring preload and in directionb

to decrease spring preload.

Make sure that the appropriate notch in

the adjusting ring is aligned with the po-

sition indicator on the rear shock ab-

sorber.CI-15E

Adjusting rebound damping force

Turn the adjusting knob in direction a

to increase rebound damping force and

in direction b to decrease rebound

damping force.CI-29E

1. Spring preload adjusting ring

2. Position indicator

SoftStan-

dardHard

Adjusting

position1 2 3 4 5 6 7

1. Rebound damping force adjusting knob

2. Position indicator







33/109


3-19

3

Adjusting compression damping

force

Turn the adjusting screw in directiona

to increase compression damping

force and in direction b to decrease

compression damping force.CI-15E

EAU00315

WARNING@

This shock absorber contains high-ly pressurized nitrogen gas. Read

and understand the following infor-

mation before handling the shock

absorber. The manufacturer cannot

be held responsible for property

damage or personal injury that may

result from improper handling.

q Do not tamper with or attempt to

open the cylinder assembly.

q Do not subject the shock ab-

sorber to an open flame or otherhigh heat source. This may

cause the unit to explode due to

excessive gas pressure.

q Do not deform or damage the

cylinder in any way. Cylinder

damage will result in poordamping performance.

q Take your shock absorber to a

Yamaha dealer for any service.@

1. Compression damping force adjusting screw

Soft Standard Hard

Adjusting

position6 5 4 3 2 1



34/109

S U CO O U C O S

3-20

3

EAU01580

Recommended combinations of the front fork and the rear shock absorber settings

Use this table as a guide for specific settings according to motorcycle load conditions.CI-31E

EC000016

CAUTION:@

Never attempt to turn the adjuster beyond the maximum or minimum setting.@

Loading condition Front fork adjustment Rear shock absorber adjustment

Spring preloadCompression

damping force

Rebound

damping forceSpring preload

Compression

damping force

Rebound

damping force

Solo rider 1 ~ 8 1 ~ 10 1 ~ 10 1 ~ 5 1 ~ 5 3 ~ 20

With passenger 1 ~ 8 1 ~ 10 1 ~ 10 3 ~ 7 4 ~ 6 0 ~ 10



35/109

3-21

3

EAU00324

Luggage strap holdersThere are four luggage strap holders

below the passenger seat, two of which

can be turned outward for easier ac-cess.

EAU00330

Sidestand

This model is equipped with an ignitioncircuit cut-off system. The motorcycle

must not be ridden when the sidestand

is down. The sidestand is located on

the left side of the frame. (Refer to

page 5-1 for an explanation of this sys-

tem.)

EW000044

WARNING@

This motorcycle must not be operat-ed with the sidestand in the down

position. If the stand is not properly

retracted, it could contact the

ground and distract the operator, re-

sulting in a possible loss of control.

Yamaha has designed into this

motorcycle a lockout system to as-

sist the operator in fulfilling the re-

sponsibility of retracting the

sidestand. Please check carefully

the operating instructions listed be-low and if there is any indication of a

malfunction, return the motorcycle

to a Yamaha dealer immediately for

repair.@

1. Luggage strap holder ( 4)



36/109

3-22

3

EAU00331

Sidestand/clutch switch

operation checkCheck the operation of the sidestand

switch and clutch switch against the in-

formation below.CD-11E

EW000045

WARNING@

If improper operation is noted, con-

sult a Yamaha dealer immediately.@

TURN THE MAIN SWITCH TO ON

AND THE ENGINE STOP SWITCH TO .

TRANSMISSION IS IN GEAR AND

SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND

PUSH THE START SWITCH.

ENGINE WILL START.

SIDESTAND IS DOWN.

CLUTCH SWITCH IS OK.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.


37/109

PRE-OPERATION CHECKS


38/109

4

Pre-operation check list...................................................................... 4-1

EAU01114

4-PRE-OPERATION CHECKS


39/109

4-1

4

Owners are personally responsible for their vehicles condition. Your motorcycles vital functions can start to deteriorate

quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or

loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-spection, you check the following points before each ride.

EAU00340

PRE-OPERATION CHECK LIST

ITEM CHECKS PAGE

Front brake Check operation, free play, fluid level and fluid leakage.

Fill with DOT 4 brake fluid if necessary.

6-23 ~ 6-26

Rear brake 6-23 ~ 6-26

Clutch Check operation condition and free play. Adjust if necessary.

6-23

Throttle grip and housing Check for smooth operation. Lubricate if necessary.

6-18, 6-28

Engine oil

Check oil level.

Fill with oil if necessary. 6-9 ~ 6-11

Coolant reservoir tank Check coolant level. Fill with coolant as required.

6-12

Drive chain Check chain slack and condition. Adjust if necessary.

6-27 ~ 6-28

Wheels and tires Check tire pressure, wear and damage. 6-19 ~ 6-22

Control and meter cable Check for smooth operation. Lubricate if necessary.

6-28

Brake and shift pedalshafts

Check for smooth operation. Lubricate if necessary.

6-29

Brake and clutch leverpivots

Check for smooth operation. Lubricate if necessary.

6-29

Sidestand pivot Check for smooth operation. Lubricate if necessary.

6-29

PRE-OPERATION CHECKS


40/109

4-2

4NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-

plished in a very short time; and the added safety it assures is more than worth the time involved.

WARNING

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating

the motorcycle.

Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened.

Tighten if necessary.

Fuel Check fuel level. Fill with fuel if necessary.

3-11 ~ 3-13

Lights, signals andswitches

Check for proper operation. 6-33 ~ 6-35

Air intake duct Check that the screen is not clogged.

Clean if necessary.

ITEM CHECKS PAGE


41/109

OPERATION AND IMPORTANT RIDING POINTS


42/109

5

Starting the engine............................................................................. 5-1

Starting a warm engine...................................................................... 5-4

Shifting ............................................................................................... 5-4

Recommended shift points (for Switzerland only) .............................. 5-5

Tips for reducing fuel consumption .................................................... 5-5

Engine break-in .................................................................................. 5-5

Parking ............................................................................................... 5-6

EAU00372

5-OPERATION AND IMPORTANT RIDING POINTS


43/109

5-1

5

EAU00373

WARNING@

q Before riding this motorcycle,become thoroughly familiar

with all operating controls and

their functions. Consult a

Yamaha dealer regarding any

control or function that you do

not thoroughly understand.q Never start your engine or let it

run for any length of time in a

closed area. The exhaust fumes

are poisonous and can cause

loss of consciousness and

death within a short time. Al-

ways operate your motorcycle

in an area with adequate ventila-

tion.

q Before starting out, always be

sure the sidestand is up. Failureto retract the sidestand com-

pletely can result in a serious

accident when you try to turn a

corner.@

EAU01627

Starting the engine

NOTE:@

This motorcycle is equipped with an ig-

nition circuit cut-off system.

The engine can be started only under

one of the following conditions:

q The transmission is in neutral.

q The sidestand is up, the transmis-

sion is in gear and the clutch is dis-

engaged.

The motorcycle must not be ridden

when the sidestand is down.@

EW000054

WARNING@

Before going through the following

steps, check the function of the

sidestand switch and clutch switch.

(Refer to page 3-22.)@



44/109

5-2

5

CF-28E

TURN THE MAIN SWITCH TO ON AND THE

ENGINE STOP SWITCH TO .

IF TRANSMISSION IS IN NEUTRAL AND

SIDESTAND IS DOWN,

PUSH THE START SWITCH.

ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT

TRANSMISSION IN GEAR.

IF TRANSMISSION IS IN GEAR AND

SIDESTAND IS UP,

PULL IN THE CLUTCH LEVER AND PUSH START

THE SWITCH. ENGINE WILL START.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.



45/109

5-3

5

1. Turn the main switch to ON and

the engine stop switch to .EC000035

CAUTION:@

If the fuel indicator light comes on,

check the fuel level. If necessary, fill

the tank with fuel.@

2. Shift the transmission into neutral.

NOTE:@

When the transmission is in neutral, the

neutral indicator light should be on. If

the light does not come on, ask a

Yamaha dealer to inspect it.@

3. Turn on the starter (choke) and

completely close the throttle grip.

4. Start the engine by pushing the

start switch.

NOTE:@

If the engine fails to start, release the

start switch, wait a few seconds, thentry again. Each attempt should be as

short as possible to preserve the bat-

tery. Do not crank the engine more

than 10 seconds on any one attempt.@

EC000036

CAUTION:@

The oil level indicator light and fuel

indicator light should come on when

the start switch is pushed and

should go off when the start switch

is released. If the oil level indicatorlight flickers or remains on, immedi-

ately stop the engine and check the

engine oil level and for oil leakage. If

necessary, fill the engine with oil

and check to see that the oil level in-

dicator light goes off. If not, consulta Yamaha dealer.@

5. After starting the engine, move the

starter (choke) to the halfway posi-

tion.

NOTE:@

For maximum engine life, never accel-

erate hard with a cold engine!@

6. After the engine is warm, turn off

the starter (choke) completely.

NOTE:@

The engine is warm when it responds

normally to the throttle with the starter

(choke) turned off.@



46/109

5-4

5

EAU01258

Starting a warm engine

The starter (choke) is not requiredwhen the engine is warm.EC000046

CAUTION:@

See the Engine break-in section

prior to operating the motorcycle for

the first time.@

EAU00423

ShiftingThe transmission lets you control the

amount of power you have available ata given speed for starting, accelerating,

climbing hills, etc. The use of the shift

pedal is shown in the illustration.

To shift into neutral, depress the shift

pedal repeatedly until it reaches the

end of its travel, then raise the pedalslightly.

EC000048

CAUTION:@

q Do not coast for long periodswith the engine off, and do not

tow the motorcycle a long dis-

tance. Even with gears in neu-

tral, the transmission is only

properly lubricated when the

engine is running. Inadequatelubrication may damage the

transmission.

q Always use the clutch when

changing gears. The engine,

transmission, and driveline are

not designed to withstand the

shock of forced shifting and can

be damaged by shifting without

using the clutch.@

1. Shift pedal

N. Neutral



47/109

5-5

5

EAU02937

Recommended shift points

(for Switzerland only)The recommended shift points areshown in the table below.CF-26E

NOTE:@

When shifting two gears down from 5th

to 3rd, bring your motorcycle to aspeed of 35 km/h.@

EAU00424

Tips for reducing fuel

consumptionYour motorcycles fuel consumptiondepends to a large extent on your

riding style. The following tips can help

reduce fuel consumption:

q Warm up the engine before riding.

q Turn off the starter (choke) assoon as possible.

q Shift up swiftly and avoid high en-

gine speeds during acceleration.

q Do not double-clutch or rev the en-

gine while shifting down and avoid

high engine speeds with no load

on the engine.

q Turn off the engine instead of let-

ting it idle for an extended length

of time, i.e. in traffic jams, at traffic

lights or railroad crossings.

EAU00436

Engine break-inThere is never a more important period

in the life of your motorcycle than the

period between zero and 1,000 km. For

this reason we ask that you carefully

read the following material. Because

the engine is brand new, you must not

put an excessive load on it for the first1,000 km. The various parts in the en-

gine wear and polish themselves to the

correct operating clearances. During

this period, prolonged full throttle oper-

ation, or any condition which might re-

sult in excessive heating of the engine,must be avoided.

Acceleration shift point

(km/h)

1st 2nd

2nd 3rd3rd 4th

4th 5th

5th 6th

20

3040

50

60



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5-6

5

EAU00440

0 ~ 150 km

Avoid operation above 8,000 r/min.

Stop the engine and let it cool for 5 to

10 minutes after every hour of opera-

tion. Vary the speed of the motorcycle

from time to time. Do not operate it at

one set throttle position.

150 ~ 500 km

Avoid prolonged operation above

9,000 r/min. Rev the motorcycle freely

through the gears, but do not use full

throttle at any time.

500 ~ 1,000 km

Avoid prolonged full throttle operation.

Avoid cruising speeds in excess of

10,000 r/min.EC000052

CAUTION:@

After 1,000 km of operation, be sure

to replace the engine oil and oil fil-

ter.@

1,000 km and beyond

Full throttle can be used.EC000053

CAUTION:@

q Never let engine speeds enter

the red zone.

q If any engine trouble should oc-

cur during the break-in period,

consult a Yamaha dealer imme-diately.

@

EAU00460

ParkingWhen parking the motorcycle, stop the

engine and remove the ignition key.EW000058

WARNING@

The exhaust system is hot. Park the

motorcycle in a place where pedes-

trians or children are not likely totouch the motorcycle. Do not park

the motorcycle on a slope or soft

ground; the motorcycle may over-

turn.@


49/109


50/109

EAU00462

6-PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00464 NOTE


51/109

6-1

6

EAU00464

Periodic inspection, adjustment and lu-

brication will keep your motorcycle in

the safest and most efficient condition

possible. Safety is an obligation of the

motorcycle owner. The maintenance

and lubrication schedule chart should

be considered strictly as a guide to

general maintenance and lubricationintervals. YOU MUST TAKE INTO

CONSIDERATION THAT WEATHER,

TERRAIN, GEOGRAPHICAL LOCA-

TIONS, AND A VARIETY OF INDIVID-

UAL USES ALL TEND TO DEMAND

THAT EACH OWNER ALTER THISTIME SCHEDULE TO SHORTER IN-

TERVALS TO MATCH THE ENVI-

RONMENT. The most important points

of motorcycle inspection, adjustment,

and lubrication are explained in the fol-

lowing pages.EW000060

WARNING@

If you are not familiar with motor-

cycle service, this work should be

done by a Yamaha dealer.@

EAU00469

Tool kitThe service information included in this

manual is intended to provide you, the

owner, with the necessary informationfor completing some of your own pre-

ventive maintenance and minor re-

pairs. The tools provided in the owners

tool kit are to assist you in the perfor-

mance of periodic maintenance. How-

ever, some other tools such as a torque

wrench are also necessary to perform

the maintenance correctly.

NOTE:@

If you do not have necessary tools re-

quired during a service operation, takeyour motorcycle to a Yamaha dealer for

service.@

EW000063

WARNING@

Modifications to this motorcycle not

approved by Yamaha may cause

loss of performance, and render it

unsafe for use. Consult a Yamaha

dealer before attempting any chang-

es.@

1. Tool kit

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00473


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6-2

6

EAU00473

PERIODIC MAINTENANCE AND LUBRICATIONCP-01E

NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL

(1,000 km)

EVERY6,000 km

or6 months

(whichevercomes first)

12,000 kmor

12 months(whichevercomes first)

1 * Fuel line Check fuel hoses and vacuum hose for cracks or damage. Replace if necessary.

2 * Fuel filter Check condition. Replace if necessary.

3 Spark plugs Check condition. Clean, regap or replace if necessary.

4 * Valves Check valve clearance. Adjust if necessary.

Every 42,000 km or 42 months(whichever comes first)

5 Air filter Clean or replace if necessary.

6 Clutch Check operation. Adjust or replace cable.

7 * Front brake

Check operation, fluid level and vehicle for fluid leakage.(See NOTE on page 6-4.)

Correct accordingly. Replace brake pads if necessary.

8 * Rear brake Check operation, fluid level and vehicle for fluid leakage.(See NOTE on page 6-4.) Correct accordingly. Replace brake pads if necessary.

9 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary.

10 * Tires

Check tread depth and for damage. Replace if necessary.

Check air pressure. Correct if necessary.


EVERY


53/109

6-3

6

11 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.

12

*Swingarm

Check swingarm pivoting point for play. Correct if necessary.

Lubricate with molybdenum disulfide grease every 24,000 km or24 months (whichever comes first).

13 Drive chain

Check chain slack. Adjust if necessary. Make sure that the rear wheel is properly

aligned. Clean and lubricate.

Every 1,000 km and after washing themotorcycle or riding in the rain

14 * Steering bearings

Check bearing play and steering for roughness. Correct accordingly.

Lubricate with lithium soap base grease every 24,000 kmor 24 months (whichever comes first).

15 * Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.

16 Sidestand Check operation. Lubricate and repair if necessary.

17 * Sidestand switch Check operation.

Replace if necessary.

18 * Front fork Check operation and for oil leakage. Correct accordingly.

19 *Rear shock absorberassembly

Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.

20 *Rear suspension relayarm and connecting arm

pivoting points

Check operation. Lubricate with molybdenum disulfide grease every 24,000 km or

24 months (whichever comes first).

NO. ITEM CHECKS AND MAINTENANCE JOBS

INITIAL

(1,000 km)

EVERY

6,000 kmor


12,000 kmor



EVERY


54/109

6-4

6

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

EAU02970*

NOTE:@

q The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

q Hydraulic brake system

When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level

regularly and fill as required. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.

Replace the brake hoses every four years or if cracked or damaged.@

21 * Carburetors Check engine idling speed, synchronization and starter operation. Adjust if necessary.

22 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary.

Change. (Warm engine before draining.)

23 Engine oil filter cartridge Replace.

24 * Cooling system

Check coolant level and vehicle for coolant leakage. Correct if necessary. Change coolant every 24,000 km or 24 months (whichever comes

first).

NO. ITEM CHECKS AND MAINTENANCE JOBS

INITIAL

(1,000 km)

EVERY

6,000 kmor


12,000 kmor




55/109

6-5

6

EAU01139*

Cowling and panel removal

and installation

The cowlings and panel illustratedneed to be removed to perform some

of the maintenance described in this

chapter.

Refer to this section each time a cowl-

ing or panel has to be removed or rein-

stalled.

EAU03036*

Cowling A and BTo remove

1. Remove the bolts.

1. Cowling A

2. Panel D

1. Cowling B

2. Cowling C

1. Bolt ( 3 on each side)



56/109

6-6

6

2. Disconnect the auxiliary light cou-

pler and the turn signal connec-

tors.

To install

1. Connect the auxiliary light coupler

and the turn signal connectors.

2. Place the cowling in the original

position and install the bolts.

1. Bolt ( 13) 1. Bolt ( 5 on each side) 1. Auxiliary light coupler

2. Turn signal connectors



57/109

6-7

6

EAU03037*

Cowling C

To remove1. Remove panel D and the right

grab bar by removing the bolts.

2. Remove the cowling by removing

the bolt.

To install

1. Place the cowling in the original

position and install the bolt.

2. Install the grab bar and then the

panel by installing the bolts.

EAU03053

Spark plugsRemoval

1. Remove the spark plug caps.

1. Cowling C

2. Bolt ( 2)

3. Right grab bar

4. Panel D

1. Bolt ( 3) 1. Spark plug cap ( 2 on each side)


Do not attempt to diagnose such prob-


58/109

6-8

6

2. Use the spark plug wrench in the

tool kit to remove the spark plugs

as shown.

Inspection

The spark plug is an important engine

component and is easy to inspect. The

condition of the spark plug can indicate

the condition of the engine.Normally, all spark plugs from the

same engine should have the same

color on the white insulator around the

center electrode. The ideal color at this

point is a medium-to-light tan color for a

motorcycle that is being ridden normal-

ly. If one spark plug shows a distinctly

different color, there could be some-

thing wrong with the engine.

p g p

lems yourself. Instead, take the motor-

cycle to a Yamaha dealer. You shouldperiodically remove and inspect the

spark plugs because heat and deposits

will cause any spark plug to slowly

break down and erode. If electrode ero-

sion becomes excessive, or if carbon

and other deposits are excessive, youshould replace the spark plug with the

specified plug.

1. Spark plug wrench

Specified spark plug:

CR9E (NGK) or

U27ESR-N (DENSO)


59/109


Left side view


60/109

6-10

6

2. With the engine stopped, check

the oil level through the level win-

dow located at the lower part of

the right side crankcase cover.

NOTE:@

Wait a few minutes until the oil level

settles before checking.@

3. The oil level should be between

maximum and minimum marks. If

the level is low, fill the engine with

sufficient oil to reach the specified

level.

Engine oil and oil filter cartridge re-

placement

1. Remove cowling A. (See page 6-5

for removal and installation proce-

dures.)2. Remove the cowling stay.

3. Warm up the engine for several

minutes.

4. Stop the engine. Place an oil pan

under the engine and remove the

oil filler cap.

5. Remove the drain bolt and drain

the oil.

6. Remove the oil filter by using an oil

filter wrench.

NOTE:@

An oil filter wrench is available at a

nearby Yamaha dealer.@

7. Reinstall the drain bolt and tighten

it to the specified torque.

1. Engine oil filler cap 1. Engine oil drain bolt

Left side view

1. Oil filter cartridge

2. Oil filter wrench

Tightening torque:Drain bolt:

43 Nm (4.3 mkg)


11. Start the engine and warm it up forTightening torque:


61/109

6-11

6

8. Apply a light coat of engine oil to

the O-ring of the new oil filter.

NOTE:@

Make sure the O-ring is seated proper-ly.@

9. Install the oil filter and tighten it to

the specified torque with an oil fil-

ter wrench.

NOTE:When installing the oil filter, tighten it to

the proper torque by using a torque

wrench.

10. Fill the engine with sufficient oil to

reach the specified level. Install

the oil filler cap and tighten it.

EC000066

CAUTION:@

q Do not put in any chemical addi-

tives. Engine oil also lubricates

the clutch and additives could

cause clutch slippage.

q Be sure no foreign material en-

ters the crankcase.@

several minutes. While warming

up, check for oil leakage. If oilleakage is found, stop the engine

immediately and check for the

cause.

NOTE:@

After the engine is started, the oil level

indicator light should go off if the oil is at

the specified level.@

EC000067

CAUTION:@

If the indicator light flickers or re-

mains on, immediately stop the en-gine and consult with a Yamaha

dealer.@

12. Install the cowling stay and cowl-

ing.

1. O-ring

Tightening torque:

Oil filter:

17 Nm (1.7 mkg)

Recommended oil:See page 8-1.

Oil quantity:

Total amount:

3.5 L

Periodic oil change:

2.6 L

With oil filter replacement:

2.9 L


Coolant reservoir capacity:


62/109

6-12

6

EAU03024

Cooling system1. Remove the seat. (See page 3-14

for seat removal and installationprocedures.)

2. Check the coolant level in the res-

ervoir tank when the engine is cold

as the coolant level will vary with

engine temperature. The coolant

level should be between the maxi-mum and minimum marks.

3. If the level is low, add coolant or

distilled water to raise it to the

specified level.

4. Install the seat.

ECA00041

CAUTION:@

Hard water or salt water is harmful

to the engine. You may use soft wa-

ter if you cant get distilled water.@

NOTE:@

q If water is added, have a Yamaha

dealer check the antifreeze con-

tent of the coolant as soon as pos-

sible.

q The radiator fan operation is com-

pletely automatic. It is switched on

or off according to the coolant tem-

perature in the radiator.@

5. If your motorcycle overheats, see

page 6-41 for details.

1. Maximum level mark

2. Minimum level mark


0.55 L



63/109

6-13

6

EAU03025

Changing the coolant1. Put the motorcycle on a level place.

2. Remove the seat. (See page 3-14for removal and installation proce-

dures.)

3. Remove cowling C. (See page 6-7

for removal and installation proce-

dures.)

4. Remove the bolts and the coolantreservoir.

5. Drain the coolant from the coolant

reservoir.

6. Remove cowlings A and B. (See

page 6-5 for removal and installa-

tion procedures.)

7. Remove the fuel tank bolts, then

lift the fuel tank upward. (Do not

remove the fuel hoses.)EW000071

WARNING@q Support the fuel tank carefully

during this procedure.

q Do not tilt the fuel tank too

much or pull it too hard because

the fuel hose connections may

become loose causing fuel

leakage.@

8. Remove the right air intake duct by

loosening and removing the screw

clamps.

1. Bolt ( 2)

2. Coolant reservoir

1. Bolt ( 2) 1. Screw clamp ( 2)

2. Right air intake duct


Recommended anti-freeze:


64/109

6-14

6

9. Remove the radiator cap.EW000067

WARNING@

Do not remove the radiator cap

when the engine is hot.@

10. Place a container under the en-

gine.

11. Remove the water pump drain bolt

and drain the coolant.

12. Remove the cylinder drain boltsand drain the coolant.

13. Install the water pump drain bolt

and cylinder drain bolts and tight-

en to the specified torque.

14. Pour the recommended coolant

into the radiator until it is full.

ECA00041

CAUTION:@

Hard water or salt water is harmful

to the engine. You may use soft wa-

ter if you cant get distilled water.@

15. Install the radiator cap.

16. Run the engine several minutes to

recheck the coolant level in the ra-

diator. If it is low, fill with morecoolant until it reaches the top of

the radiator.

17. Check for coolant leakage.

1. Radiator cap 1. Water pump drain bolt

2. Cylinder drain bolt ( 2)

Tightening torque:

Drain bolt:

10 Nm (1.0 mkg)

High quality ethylene glycol anti-

freeze containing corrosion inhib-itors for aluminum engines.

Antifreeze and water mix ratio:

1:1

Total amount:

1.95 L


0.55 L


NOTE:@

If you find any leaks ask a Yamaha


65/109

6-15

6

If you find any leaks, ask a Yamaha

dealer to inspect.@

18. Install the right air intake duct, then

install and tighten the screw

clamps.

19. Install the fuel tank and fuel tank

bolts.

20. Install the coolant reservoir and

bolts.

21. Fill the coolant reservoir with the

recommended coolant to the

specified level.

22. Install cowlings A and B.

23. Install cowling C.

24. Install the seat.

EAU01475

Air filterThe air filter should be cleaned at the

specified intervals. It should be cleaned

more frequently if you are riding in un-usually wet or dusty areas.

1. Remove the seat.

2. Remove the bolts holding the fuel

tank.

3. Lift the fuel tank upward and posi-

tion it away from the air filter case.(Do not remove the fuel hoses.)

EW000071

WARNING@

q Support the fuel tank carefully

during this procedure.

q Do not tilt the fuel tank toomuch or pull it too hard because

the fuel hose connections may

become loose causing fuel

leakage.@

4. Remove the screws holding the airfilter case cover.

1. Bolt ( 2) 1. Air filter case cover


EC000082

CAUTION:


66/109

6-16

6

5. Pull out the air filter.

6. Remove the air filter from its guide

and clean it with solvent. After

cleaning, squeeze the air filter toremove the remaining solvent.

7. Apply recommended oil to the en-

tire surface of the filter and

squeeze out the excess oil. The air

filter should be wet but not drip-

ping.

CAUTION:@

q Make sure the air filter is prop-

erly seated in the air filter case.

q The engine should never be run

without the air filter installed.

Excessive piston and/or cylin-

der wear may result.@

8. Reverse the removal procedures

for installation.EW000131

WARNING@

Make sure that the fuel hoses and

vacuum hose are properly connect-

ed, in place and not pinched. If a

hose is damaged, be sure to replace

it.@

1. Air filter element

2. Air filter guide

Recommended oil:

SAE 10W30 type SE motor oil


EAU00630

Carburetor adjustment


67/109

6-17

6

EAU00626

Air vent hoseIf dust or water collects in this hose, re-

move the hose and clean it.EC000093

CAUTION:@

Do not operate the motorcycle with

the air vent hose removed.@

EAU01335

Air intake ductCheck that the screen of the intake

duct is not blocked. Clean the screen if

necessary.

The carburetors are important parts of

the engine and require very sophisti-

cated adjustment. Most adjustments

should be left to a Yamaha dealer who

has the professional knowledge and

experience to do so. However, the idle

speed may be adjusted by the owneras part of routine maintenance.EC000095

CAUTION:@

The carburetors were set at the

Yamaha factory after many tests. If

they are changed, poor engine per-formance and damage may result.@

1. Hose 1. Air intake duct


EAU00632

Idle speed adjustment


68/109

6-18

6

1. Start the engine and warm it up for

a few minutes at approximately

1,000 to 2,000 r/min. Occasionally

rev the engine to 4,000 to

5,000 r/min. The engine is warm

when it quickly responds to the

throttle.

2. Set the idle to the specified engine

speed by adjusting the throttle

stop screw. Turn the screw in di-

rection a to increase engine

speed and in direction b to de-crease engine speed.

NOTE:@

If the specified idle speed cannot be

obtained by performing the above ad-

justment, consult a Yamaha dealer.@

EAU00635

Throttle cable free play

inspectionThere should be a free play of 3 ~

7 mm at the throttle grip. If the free playis incorrect, ask a Yamaha dealer to

make this adjustment.

1. Throttle stop screw

Standard idle speed:

1,200 ~ 1,300 r/min

a. Free play


EAU00637

Valve clearance adjustmentEAU00658

TiresCE-33E

Maximum load*180 kg (except for A, CH, S)

178 kg (for A, CH, S)


69/109

6-19

6

The correct valve clearance changes

with use, resulting in improper fuel/air

supply or engine noise. To prevent this,

the valve clearance must be adjusted

regularly. This adjustment however,

should be left to a professional

Yamaha service technician.

To ensure maximum performance,

long service and safe operation, note

the following:

Tire air pressure

Always check and adjust the tire pres-

sure before operating the motorcycle.EW000082

WARNING@

Tire inflation pressure should be

checked and adjusted when the

temperature of the tire equals the

ambient air temperature. Tire infla-tion pressure must be adjusted ac-

cording to total weight of cargo,

rider, passenger, and accessories

(fairing, saddlebags, etc. if approved

for this model), and vehicle speed.@

Cold tire pressure Front Rear

Up to 90 kg load*

225 kPa

(2.25 kg/cm2,

2.25 bar)

250 kPa

(2.50 kg/cm2,

2.50 bar)

90 kg Maximum load*

250 kPa

(2.50 kg/cm2,

2.50 bar)

290 kPa

(2.90 kg/cm2,

2.90 bar)

High speed riding

250 kPa

(2.50 kg/cm2

,2.50 bar)

290 kPa

(2.90 kg/cm2

,2.90 bar)

* Load is the total weight of cargo, rider, passenger

and accessories.


EW000083

WARNING@

EW000095

WARNING@


70/109

6-20

6

@

Proper loading of your motorcycle

is important for several characteris-

tics of your motorcycle, such as

handling, braking, performance and

safety. Do not carry loosely packed

items that can shift. Securely pack

your heaviest items close to thecenter of the motorcycle, and dis-

tribute the weight evenly from side

to side. Properly adjust the suspen-

sion for your load, and check the

condition and pressure of your tires.

NEVER OVERLOAD YOUR MOTOR-CYCLE. Make sure the total weight

of the cargo, rider, passenger, and

accessories (fairing, saddlebags,

etc. if approved for this model) does

not exceed the maximum load of the

motorcycle. Operation of an over-

loaded motorcycle could cause tire

damage, an accident, or even injury.@

Tire inspection

Always check the tires before operating

the motorcycle. If center tread depth

reaches the limit as shown, if the tirehas a nail or glass fragments in it, or if

the side wall is cracked, contact a

Yamaha dealer immediately and have

the tire replaced.

@

Operating the motorcycle with ex-

cessively worn tires decrease riding

stability and can lead to loss of con-

trol. Have excessively worn tires re-

placed by a Yamaha dealer

immediately. Brakes, tires, and relat-

ed wheel parts replacement shouldbe left to a Yamaha Service Techni-

cian.@

CE-26E

NOTE:@

These limits may be different by regula-

tion from country to country. If so, con-

form to the limits specified by the

regulations of your own country.@

1. Side wall

a. Tread depth

Minimum tire tread depth

(front and rear)1.6 mm


EW000080

WARNING@

CE-10EFRONT

Manufacturer Size Type


71/109

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6

Tire information

This motorcycle is equipped with tube-

less tires, tire valves and cast wheels.

@

q After extensive tests, the tires

mentioned below have been ap-

proved by Yamaha Motor Co.,

Ltd. for this model. No guaran-

tee for handling characteristics

can be given if tire combina-

tions other than what is ap-proved are used on this

motorcycle. The front and rear

tires should be of the same

manufacture and design.

q The use of tire valves and valve

cores other than listed belowcould cause tire deflation dur-

ing extreme high speed riding.

Always use genuine parts or

their equivalent for replace-

ment.

q Be sure to install the valve caps

securely, as these are important

to prevent air pressure leakage

during extreme high speed

riding.@

CE-12E

1. Tire valve

2. Valve core

3. Valve cap with seal

Dunlop 120/60 ZR17 (55 W) D204F

Metzeler 120/60 ZR17 (55 W) MEZ1 Front

Bridgestone 120/60 ZR17 (55 W) BT57F

Michelin 120/60 ZR17 (55 W) MACADAM 90X

REAR

Manufacturer Size Type

Dunlop 160/60 ZR17 (69 W) D204

Metzeler 160/60 ZR17 (69 W) MEZ1

Bridgestone 160/60 ZR17 (69 W) BT57

Michelin 160/60 ZR17 (69 W) MACADAM 90X

Type

Tire valve TR412

Valve core #9000A (original)


EAU00684

WARNING@

EAU00687

WheelsTo ens re ma im m performance


72/109

6-22

6

This motorcycle is fitted with super

high-speed running tires. The fol-

lowing points must be observed in

order for you to make fully effective

use of these tires.

q Never fail to use the specified

tires in tire replacement. Othertires may have a danger of

bursting at super high-speeds.

q New tires have a relatively low

grip on the road surface until

they have been slightly worn.

Therefore, approximately 100 kmshould be traveled at normal

speed before any high-speed

riding is done.

q Before any high-speed runs, the

tires should be warmed-up suf-

ficiently.

q Always inflate to the correct tire

pressure according to the oper-

ating conditions.@

To ensure maximum performance,

long service, and safe operation, notethe following:

q Always inspect the wheels before

a ride. Check for cracks, bends, or

warpage of the wheels. If any ab-

normal condition exists in a wheel,

consult a Yamaha dealer. Do not

attempt even small repairs to the

wheel. If a wheel is deformed or

cracked, it must be replaced.

q Tires and wheels should be bal-

anced whenever either one ischanged or replaced. Failure to

have a wheel balanced can result

in poor performance, adverse han-

dling characteristics, and short-

ened tire life.

q Ride at moderate speeds afterchanging a tire since the tire sur-

face must first be broken in for it to

develop its optimal characteristics.


NOTE:@

If proper adjustment cannot be ob-

i d h l h d k


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6

EAU00692

Clutch lever free play

adjustmentThe clutch lever free play should be ad-

justed to 10 ~ 15 mm. If the free play is

incorrect, adjust as follows.

1. Loosen the locknut.

2. Turn the adjusting bolt at the

clutch lever in direction a to in-crease free play or in direction b

to decrease free play.

3. Tighten the locknut.

tained or the clutch does not work cor-

rectly, ask a Yamaha dealer to inspect

the internal clutch mechanism.@

EAU00712

Rear brake pedal height

adjustmentThe top of the brake pedal should be

positioned 42 mm below the top of thefootrest. If not, ask a Yamaha dealer to

adjust it.

1. Locknut

2. Adjusting bolt

c. Free play

a. Pedal height


EW000109

WARNING@

A ft f li i th b k


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6

A soft or spongy feeling in the brake

pedal can indicate the presence of

air in the brake system. This air

must be removed by bleeding the

brake system before the motorcycle

is operated. Air in the system will

cause greatly diminished brakingcapability and can result in loss of

control and an accident. Have a

Yamaha dealer inspect and bleed

the system if necessary.@

EAU00713

Brake light switch adjustmentThe rear brake light switch is activated

by the brake pedal and is properly ad-

justed when the brake light comes on

just before braking takes effect. To ad-

just the rear brake light switch, hold the

switch body so it does not rotate while

turning the adjusting nut. Turn the ad-

justing nut in direction a to make thebrake light come on earlier.

Turn the adjusting nut in directionb to

make the brake light come on later.

1. Brake light switch

2. Adjusting nut


Front Rear Front


75/109

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6

EAU00715

Checking the front and rear

brake padsA wear indicator is provided on each

brake. This indicator allows checking ofbrake pad wear without disassembling

the brake. Apply the brake and inspect

the wear indicator. If the indicator is

ALMOST in contact with the disc plate,

ask a Yamaha dealer to replace the

pads.

EAU00731

Inspecting the brake fluid

level

Insufficient brake fluid may let air enterthe brake system, possibly causing the

brakes to become ineffective.

Before riding, check that the brake fluid

is above the minimum level and replen-

ish when necessary.

Observe these precautions:q When checking the fluid level,

make sure the top of the master

cylinder is level by turning the han-

dlebars.

1. Wear indicator ( 2) 1. Wear indicator ( 2) 1. Minimum level mark

2. Maximum level mark


q Be careful that water does not en-

ter the master cylinder when refill-

ing Water will significantly lower

EAU00742

Brake fluid replacementThe brake fluid should be replaced only

Rear


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6

q Use only the designated quality

brake fluid. Otherwise, the rubber

seals may deteriorate, causing

leakage and poor brake perfor-

mance.

q Refill with the same type of brake

fluid. Mixing fluids may result in a

harmful chemical reaction andlead to poor brake performance.

ing. Water will significantly lower

the boiling point of the fluid and

may result in vapor lock.

q Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Al-

ways clean up spilled fluid

immediately.q Have a Yamaha dealer check the

cause if the brake fluid level goes

down.

The brake fluid should be replaced only

by trained Yamaha service personnel.Have the Yamaha dealer replace the

following components during periodic

maintenance or when they are dam-

aged or leaking:

q oil seals (every two years)

q brake hoses (every four years)1. Minimum level mark

Recommended brake fluid: DOT 4


EC000096

CAUTION:@

Too little chain slack will overload


77/109

6-27

6

EAU00744

Drive chain slack check

NOTE:@

Spin the wheel several times and find

the tightest position of the chain. Checkand/or adjust the chain slack while its

in this tightest position.@

To check the chain slack the motor-

cycle must be held straight up with both

wheels on the ground and without rider.Check the slack at the position shown

in the illustration. Normal slack is ap-

proximately 20 ~ 30 mm. If the slack

exceeds 30 mm, adjust.

EAU00762

Drive chain slack adjustment1. Loosen the axle nut.2. Loosen the locknuts on each side.

To tighten the chain, turn the chain

adjusting nuts in direction a. To

loosen the chain, turn the adjusting

nuts in direction b and push thewheel forward. Turn each adjust-

ing nut exactly the same amount to

maintain correct axle alignment.

There are marks on each side of

the swingarm. Use these marks to

align the rear wheel.

Too little chain slack will overload

the engine and other vital parts.

Keep the slack within the specified

limits.@

3. After adjusting, tighten the lock-

nuts. Then tighten the axle nut to

the specified torque.a. Chain slack 1. Axle nut2. Alignment marks

3. Adjusting nut

4. Locknut

5. Wheel axle guide

Tightening torque:

Axle nut:

115 Nm (11.5 mkg)


EAU03006

Drive chain lubricationThe chain consists of many parts which

EAU02962

Cable inspection and

lubrication

EAU00773

Throttle cable and grip

lubrication


78/109

6-28

6

y p

work with each other. If the chain is notmaintained properly, it will wear out

quickly. Therefore, the chain must be

serviced regularly. This service is es-

pecially necessary when riding in dusty

areas. This motorcycle is equipped

with a sealed type chain. Steam clean-

ing, high-pressure washers, and sol-

vents can damage the drive chain, so

do not use these for cleaning it. Use

only kerosene to clean the drive chain.

Wipe it dry, and thoroughly lubricate itwith SAE 30 ~ 50W motor oil. Do not

use any other lubricants on the drive

chain. They may contain solvents that

could damage the sealed chain.EC000097

CAUTION:@Be sure to oil the chain after wash-

ing the motorcycle or riding in the

rain.@

lubricationEW000112

WARNING@

Damage to the outer housing of ca-

bles may lead to internal rusting and

interfere with the cable movement.

Replace damaged cables as soon as

possible to prevent unsafe condi-

tions.@

Lubricate the cables and cable ends. If

a cable does not operate smoothly, ask

a Yamaha dealer to replace it.

lubricationThe throttle twist grip assembly should

be greased at the time that the cable is

lubricated, since the grip must be re-

moved to get at the end of the throttle

cable. After removing the screws, hold

the end of the cable up in the air andput in several drops of lubricant. With

the throttle grip disassembled, coat the

metal surface of the grip assembly with

a suitable all-purpose grease.

Recommended lubricant:

Engine oil


EAU02984

Brake and shift pedal

lubrication

EAU02985

Brake and clutch lever

lubrication

EAU02986

Sidestand lubricationLubricate the sidestand pivoting point


79/109

6-29

6

Lubricate the pivoting parts. Lubricate the pivoting parts.

p g p

and metal-to-metal contact surfaces.Check that the sidestand moves up

and down smoothly.

EW000113

WARNING@

If the sidestand does not move

smoothly, consult a Yamaha dealer.@


Engine oil


Engine oilRecommended lubricant:

Engine oil


EAU00790

Rear suspension lubricationLubricate the pivoting parts.

EAU02939

Front fork inspectionVisual check


80/109

6-30

6

EW000115

WARNING@

Securely support the motorcycle so

there is no danger of it falling over.@

Check for scratches or damage on the

inner tube and excessive oil leakagefrom the front fork.

Operation check

1. Place the motorcycle on a level

place.

2. Hold the motorcycle in an upright

position and apply the front brake.3. Push down hard on the handle-

bars several times and check if the

fork rebounds smoothly.EC000098

CAUTION:@

If any damage or unsmooth move-ment is found with the front fork,

consult a Yamaha dealer.@


Molybdenum disulfide grease


EW000115

WARNING@

Securely support the motorcycle so

EAU01144

Wheel bearingsIf there is play in the front or rear wheel


81/109

6-31

6

EAU00794

Steering inspectionPeriodically inspect the condition of the

steering. Worn out or loose steering

bearings may be dangerous. Place astand under the engine to raise the

front wheel off the ground. Hold the

lower end of the front forks and try to

move them forward and backward. If

any free play can be felt, ask a Yamaha

dealer to inspect and adjust the steer-ing. Inspection is easier if the front

wheel is removed.

y pp y

there is no danger of it falling over.@

hub or if the wheel does not turnsmoothly, have a Yamaha dealer in-

spect the wheel bearings.


EAU00800

BatteryThis motorcycle is equipped with a

EW000116

WARNING@

Battery electrolyte is poisonous and

Battery storage

When the motorcycle is not used for a

month or longer, remove the battery,


82/109

6-32

6

sealed-type battery. Therefore it is notnecessary to check the electrolyte or fill

the battery with distilled water.

q If the battery seems to have dis-

charged, consult a Yamaha deal-

er.

q If the motorcycle is equipped with

optional electrical accessories, the

battery tends to discharge more

quickly, so be sure to recharge it

periodically.EC000101

CAUTION:@

Never try to remove the sealing caps

of the battery cells. The battery will

be damaged.@

dangerous, causing severe burns,

etc. It contains sulfuric acid. Avoid

contact with skin, eyes or clothing.

ANTIDOTE:

q EXTERNAL: Flush with water.

q

INTERNAL: Drink large quanti-ties of water or milk. Follow with

milk of magnesia, beaten egg,

or vegetable oil. Call a physi-

cian immediately.

q EYES: Flush with water for

15 minutes and get promptmedical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes etc.,

away. Ventilate when charging or

using in an enclosed space. Always

shield your eyes when working near

batteries.

KEEP OUT OF REACH OF CHIL-

DREN.@

g , y,

fully charge it and store it in a cool, dry

place.EC000102

CAUTION:@

q Completely recharge the bat-

tery before storing. Storing adischarged battery can cause

permanent battery damage.

q Use a battery charger designed

for a sealed-type (MF) battery.

Using a conventional battery

charger will cause battery dam-age. If you do not have a sealed-

type battery charger, contact

your Yamaha dealer.

q Always make sure the connec-

tions are correct when reinstall-

ing the battery.@



83/109

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6

EAU00819

Fuse replacementThe fuse box is located under the riderseat and the main fuse case is at-

tached to the starter relay. If any fuse is

blown, turn off the main switch and the

switch of the circuit in question. Install a

new fuse of specified amperage. Turnon the switches and see if the electrical

device operates. If the fuse immediate-

ly blows again, consult a Yamaha deal-

er. It is recommended that the main

fuse be replaced by a Yamaha dealer.

EC000103

CAUTION:@

Do not use fuses of higher amper-

age rating than those recommend-

ed. Substitution of a fuse ofimproper rating can cause extensive

electrical system damage and pos-

sibly a fire.@

EAU00826

Headlight bulb replacementThis motorcycle is equipped with a

quartz bulb headlight. If the headlight

bulb burns out, replace the bulb as fol-

lows:

1. Remove the headlight connector

and the bulb holder cover.

1. Headlight fuse

2. Signaling system fuse

3. Ignition fuse

4. Fan fuse

5. Spare fuse ( 2)

1. Main fuse

Specified fuses:

Main fuse: 30 A

Headlight fuse: 20 A

Signaling system fuse: 15 A

Fan fuse: 7.5 A

Ignition fuse: 7.5 A

1. Connector

2. Bulb cover

PERIODIC MAINTENANCE AND MINOR RE

Documents

Owners Manual U4TVE4 1999